Your production process has four steps:
	Step 1 - one worker	Drier for the plastics	capacity 5000 lbs/hr	1 flamingo = 5.0 lbs
	Step 2 - two workers	Molding machine	capacity 50 10 packs per hour
	Step 3 - three workers	Visual inspection and finishing touches		6 sec per flamingo per worker
	Step 4 - two workers	packing in boxes of 10; attaching labels		1 minute per box per worker
	Output in units (10-packs) per hour	Processing time (sec) (10-pack)	Takt Time (sec) (10 pack)	Slack (sec)	Time Idle (%)
S1
S2
S3
S4
Q8.	There seems to be a lot of waste and idle time at the plant. How many workers can you let go at station 3
a.	none
b.	one
c.	two
d.	you need to add a worker
	Output in units (10-packs) per hour	Processing time (sec) (10-pack)	Takt Time (sec) (10 pack)	Slack (sec)	Time Idle (%)
S1
S2
S3
S4
Q9.	You decide to let go all the redundant workers, in both shifts. What are the total savings ?
	Remember: your average worker costs you US$ 50,000 a year
a.	$ 200,000	per year
b.	$ 300,000	per year
c.	$ 150,000	per year
d.	$ 100,000	per year

You would like your plant to run like a well-oiled machine but a month after investing US$ 600,000 dollars to replace machinery and hire a new supply chian manager - upon visiting the factory you see some workers working non-stop and others walking around chatting and laughing. Now that you are a business owner, you think this is not a good sign ... so you look into it.
First you establish the plant's takt time - the max time available to produce a unit (10 pack) and meet demand (now 200,000 units). You have 2 shifts of 8 hours each 5 days a week for 50 weeks a year
total seconds = 2 machines 2 shifts 8 hours 5 days a week 50 weeks a year